Method of filling and sealing a microtrench and a sealed microtrench

ABSTRACT

Provided is a microtrench fill comprising cement, a polymer, and a colorant. Also provided is a method of using the microtrench fill to fill a microtrench in a roadway.

FIELD OF THE INVENTION

The invention generally relates to a method of continuously filling andsealing a microtrench.

BACKGROUND OF THE INVENTION

Conventional devices for the trenching and laying cable or duct cannotbe used continuously. The micro trencher saw usually creates a pile ofspoil (dirt, asphalt, concrete, etc.) alongside the formed trench andthe trench must be cleaned before laying the cable in the trench. Thepile of spoil must then be removed. A fill, also referred to as cementor grout, is inserted into the trench on top of the cable orinnerduct/microduct. Large industrial vacuum trailers have been used toremove the piled up spoil. However, many hours are wasted by having todump the spoil from the trailers.

There is a great need for a device that can be used to continuouslyremove and in some instances recycle the spoil to in effort to increasethe speed for placing the cable and/or innerduct/microduct and to reducethe down time of roadways, and also to reduce production costs.

While the Vacuum truck concept is known in the industry, there is nocurrent vacuum system that allows one to use a second vacuum or onevacuum to expel the cutting spoils into a cement/zim mixer or containerallowing for the material to be recycled.

Installing new optical fiber networks to a location is expensive andtime consuming. There is a great need for faster and less expensiveinstallation of optical fiber networks.

SUMMARY OF THE INVENTION

An objective of the invention is to provide an improved microtrench filland a method of continuously filling a microtrench.

The above objectives and other objectives can be obtained by a method offilling and sealing a microtrench on a roadway to return the roadway toan original state with a color-matched, filled and sealed microtrenchcomprising:

-   -   forming a flowable concrete-based fill in a fill device by        mixing together a cement, a polymer bonding agent, a colorant,        an aggregate, and water, wherein the colorant provides the        flowable concrete-based fill with a color substantially matching        the color of the roadway, the polymer bonding agent provides        adhesion to the existing roadway to seal the microtrench against        water infiltration, the flowable concrete-based fill having a        final set time of 2 hour or less, and the flowable        concrete-based fill is configured to flow into the microtrench        from a fill device; and    -   continuously filling the microtrench with the flowable        concrete-based fill material from the fill device to cover the        optical fiber and/or innerduct/microduct, fill and seal the        microtrench and return the roadway substantially back to an        original state with the color-matched, filled and sealed        microtrench.

The above objectives and other objectives can be obtained by a method offilling and sealing a microtrench on a roadway to return the roadway toan original state with a color-matched, filled and sealed microtrenchcomprising:

-   -   forming a flowable concrete-based fill in a fill device by        mixing together a cement, a polymer bonding agent, an aggregate,        and water, wherein the polymer bonding agent provides adhesion        to the existing roadway, the flowable concrete-based fill having        a final set time of 2 hour or less, and the flowable        concrete-based fill is configured to flow into the microtrench        from a fill device; and    -   continuously filling the microtrench with the flowable        concrete-based fill material from the fill device to        simultaneously cover the optical fiber and/or        innerduct/microduct, fill and seal the microtrench and return        the roadway substantially back to an original state with the        filled and sealed microtrench.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a side view of a multifunctional reel carrier, spoilmaterial handling container device.

FIG. 2 illustrates a side view of a multifunctional reel carrier, spoilmaterial handling container device.

FIG. 3 illustrates a view of the multifunctional reel carrier, spoilmaterial handling container device connected to a micro trencher and afill device.

FIG. 4 illustrates a view of the multifunctional reel carrier, spoilmaterial handling container device connected to a micro trencher and afill device.

FIG. 5 illustrates a view of another embodiment of the multifunctionalreel carrier, spoil material handling container device connected to amicro trencher and a fill device.

FIG. 6A illustrates a container device having an intake system.

FIG. 6B illustrates a container device having a sloping floor.

FIG. 6C illustrates a container device having a mechanical movingsystem.

FIG. 6D illustrates a container device having a moving inlet device.

FIG. 6E illustrates a container device having a dump body.

FIG. 7 illustrates a reel.

FIG. 8A illustrates an embodiment of the truck 124 showing how thecontainer device can be dumped.

FIG. 8B illustrates an embodiment of the truck 124 showing how thecontainer device can be dumped.

FIG. 8C illustrates an intake system for the container device.

FIG. 8D illustrates an embodiment of the truck 124 showing how thecontainer device can be dumped.

FIG. 8E illustrates an intake system for the container device

FIG. 9A illustrates an embodiment of spoil transport device.

FIG. 9B illustrates an embodiment of spoil transport device.

FIG. 10 illustrates a marker line.

FIG. 11A illustrates a sidewalk and curb having a temporary opticalfiber network and micro-trenches cut to move the temporary optical fibernetwork into a permanent position.

FIG. 11B illustrates a box having optical fiber that can be dispensed asneeded.

FIG. 11C illustrates a reel of optical fiber connected to a splitter.

FIG. 11D illustrates a reel of optical fiber connected to a splitter.

FIG. 11E illustrates a reel of optical fiber.

FIG. 11F illustrates a reel of optical fiber.

FIG. 11G illustrates a loose coil of optical fiber.

FIG. 12 illustrates a device identifier fill over a buried device.

FIG. 13 illustrates a device for applying the device identifier fill.

DETAILED DESCRIPTION OF THE INVENTION

In the following description, for purposes of explanation and notlimitation, specific details are set forth, such as particular networks,communication systems, computers, terminals, devices, components,techniques, data and network protocols, software products and systems,operating systems, development interfaces, hardware, etc. in order toprovide a thorough understanding of the present invention with referenceto the attached non-limiting figures.

However, it will be apparent to one skilled in the art that the presentinvention may be practiced in other embodiments that depart from thesespecific details. Detailed descriptions of well-known networks,communication systems, computers, terminals, devices, components,techniques, data and network protocols, software products and systems,operating systems, development interfaces, and hardware are omitted soas not to obscure the description.

As shown in FIGS. 1-4, the multifunctional reel carrier, spoil materialhandling container device 100 comprises a trader or truck bed 102 sothat the multifunctional reel carrier, spoil material handling containerdevice 100 can be moved along with a micro trencher 2. The size of thetrailer or bed 102 can be any desired size, for example from 5 to 40feet. The multifunctional reel carrier, spoil material handlingcontainer device 100 includes at least a first container 104 sized tohold spoil 12 created by the saw (such as a cutting wheel) 10 cutting amicrotrench 11, for example from 50 to 4,000 cubic feet in size. Thefirst container 104 is constructed to hold the spoil 12. A first vacuumdevice 110 has an inlet 111 disposed at the micro trencher 2 to suck upthe spoil 12, and optionally to also remove spoil 12 from themicrotrench 11. An outlet 112 of the first vacuum device 110 depositsthe spoil 12 into the first container 104. A second vacuum device 114has an inlet 115 connected to the first container 104 to remove spoilfrom the first container 104 and an outlet 116 connected to a filldevice 200. Thus, the multifunctional reel carrier, spoil materialhandling container device 100 is constructed to move spoil 12 from themicro trencher 2 to the first container 104 and then to the fill device200. Instead of the fill device 200, the second vacuum device 114 canmove the spoil to a truck or other vehicle 300 for removal of the spoilfrom the job site or to recycle the spoil back into the microtrench. Thefirst container 104 has at least one outlet 118 can have a filter toprevent spoil from being ejected into the air. The outlet 118 can allowair to enter or leave the first container 104. The reel loader 104includes at least one reel holder 120 constructed to hold a reel ofcable or innerduct/microduct 121. The multifunctional reel carrier,spoil material handling container device 100 preferably includes aplurality of reel holders 120 that can be adjusted in height and movedmanually or mechanically/hydraulically from front to back, back tofront, side to side, or up and down.

To facilitate vacuuming of the spoil 12 from the container 104,different methods to move the spoil 12 within the container 104 can beutilized. Examples of suitable methods include, but are not limited to asloping floor 119 or mechanical moving systems 117 such as augers orconveyors or a tilting mechanism such as a dump body 129. Alternatively,an inlet moving device 123 for moving an inlet hose 127 within thecontainer 104 can be utilized. In another embodiment the outlet 112 canbe connected to the inlet 115 using a connection such as a valve.

As shown in FIG. 7, the reel holders 120 can be adjustable in height andlocation either manually or mechanically 143, such as using a tread orlocking rail system, to accommodate different size reels. Multiple reelholders 120 can be utilized so that multiple cables and/or ducts 121 canbe laid in the trench 11 simultaneously. The reel holders can also havemanual or mechanical/automatic winding systems 145 allowing the cable,innerduct/microduct to be easily removed from the reels 121 and placedin the trench 11.

Any suitable micro trencher 2 can be utilized in the present invention.Non-limiting examples of suitable micro trenchers include those made andsold by Ditch Witch, Vermeer, and Marais. A micro trencher is a “smallrock wheel” specially designed for work in rural or urban areas. Themicro trencher 2 is fitted with a saw 10 that cuts a microtrench 11 withsmaller dimensions than can be achieved with conventional trench diggingequipment. Microtrench 11 widths usually range from about 6 mm to 130 mm(¼ to 5 inches) with a depth of 500 mm (20 inches) or less. Other widthsand depths can be used as desired. For example, up to 30 inches deep canbe used.

With a micro trencher 2, the structure of the road, sidewalk, driveway,or path is maintained and there is no associated damage to the road.Owing to the reduced trench size, the volume of waste material excavatedis also reduced. Micro trenchers 2 are used to minimize traffic orpedestrian disturbance during cable laying. A micro trencher 2 can workon sidewalks or in narrow streets of cities, and can cut harder groundthan a chain trencher, including cutting through for example but notlimited to solid stone, concrete, and asphalt. The term ground as usedherein includes, soil, asphalt, stone, concrete, grass, dirt, sand,brick, cobblestone, or any other material the trench 11 is cut into andthe optical fiber buried within.

FIG. 5 shows another exemplary embodiment of the present invention. Amicro trencher 2 is used to cut a micro trench 11. The multifunctionalreel carrier, spoil material handling container device 100 is separatedinto a container carrier device 240 comprising a truck 124 and reelcarrier device 242 comprising a trailer 125 so that the containercarrier device 240 and reel carrier device 242 can be moved along with amicro trencher 2. The trailer 125 can be a separate truck if desiredinstead of a trader. The container carrier device 240 includes at leasta first container 104 sized to hold spoil 12 created by the saw 10cutting a microtrench 11. The first container 104 is constructed to holdthe spoil 12. A vacuum device 130 has an inlet 111 disposed at the microtrencher 2 to suck up the spoil 12, and optionally to also remove spoil12 from the microtrench 11. The inlet 111 comprises a hose. The inlet111 can be connected to the container 104 and the vacuum device 130connected to the container 104 so that when a vacuum is pulled on thecontainer 104, the spoil 12 is sucked through the inlet 111 into thecontainer 104. In this instance, the container 104 can be constructed tosubstantially maintain its shape when a vacuum is pulled. A safety valvecan be present to prevent too much of a vacuum being pulled on thecontainer 104. Alternatively, the inlet 111 can be connected to thevacuum device 130 and the spoil deposited into the container 104. Thevacuum device 130 has an intake system 113 or inlet 127 inside thecontainer 104 to suck up spoil 12 inside the container 104. An outlet116 of the vacuum device 130 transfers the spoil 12 to the fill device200 or to another vehicle 300 as shown in FIG. 4. Alternatively, thetruck 124 can be fitted with two vacuum devices 110 and 114 as shown inFIG. 4 in place of the single vacuum device 130. Thus, the containercarrier device 240 is constructed to move spoil 12 from the microtrencher 2 to the first container 104 and then to the fill device 200.The reel carrier device 242 comprises at least one reel holder 120.

As shown in FIGS. 6A-6E, the container 104 can be any desired shape,such as square, rectangular, or tubular and hold anywhere from 1 cu yardof spoil to 100 yds of spoil 12. The spoil intake, inlet 111, can be anydesired location on the container 104, such as on the top, back, frontor side of the container 104 or connected to the container 104 via thevacuum 110 or 130. Spoil removal intake system 113 or inlet 127 can belocated in any desired position in the container 104, such as on thebottom, side, front or rear. The intake system 113 can have one largeopening or multiple smaller openings spread out to remove the spoil 12evenly from the container 104. The container 104 can have an opening anda lifting device 129, such as hydraulics, to lift or tilt the container104 to move the spoil within the container 104 or to remove the spoilfrom the container. For example, the container 104 can be part of dumptruck. Thus, the container 104 can have the ability to off load spoil 12by tilting to either side to dump the spoil 12 through a door 183 or canbe raised, expelling the spoil 12 from the rear. The side wall(s) and orback of the container 104 can be locked manually or hydraulically toensure no spoil 12 or dust can leak out during the vacuum intake orouttake process. A fill gauge 160 can be installed showing how full thecontainer 104 is. An air valve 163 can be installed to adjust the airpressure inside of the container 104, such as allowing air to be removedduring and after operation when spoil 12 passes through the vacuumdevice and then into container 104 as shown in FIG. 4, or to allow airinto the container 104 to prevent too low of a vacuum in the container104 when the spoil 12 is sucked directly into the container as shown inFIG. 5. An air filter 167 can be installed allowing air to be releasedreducing pressure build up in the container 104 while containing dustinside of the container 104. Pressure gauge 161 can be installed tomonitor the pressure in the container 104. The interior of the container104 can have a stationary slant in the bed 119 or a mechanical bed 117to help move the spoil 112 to a designated release point.

A conventional vacuum truck can be modified to remove spoil 12 from thecontainer 104 by adding the intake system 113, adding an outlet 116 tofill device 200, and modifying the vacuum device 130 and/or adding anadditional vacuum device to transfer spoil 12 from the saw 10 to thecontainer 104 and to the fill device 200. FIGS. 8A-8E illustrate amodified vacuum dump truck 124.

The multifunctional reel carrier, spoil material handling containerdevice 100 (FIG. 5) and the reel carrier 240 (FIG. 4) can each includesat least one reel holder 120 constructed to hold a reel of cable orinnerduct/microduct 121. The multifunctional reel carrier, spoilmaterial handling container device 100 and the reel carrier 240 eachpreferably includes a plurality of reel holders 120 that can be adjustedin height 143 and moved manually or mechanically/hydraulically fromfront to back, back to front, side to side, or up and down. To reducethe overall height of the device, the reel holders 120 can be mounted ona separate trailer 125 that is towed by the truck 124.

The first vacuum device 110 and second vacuum device 114, and vacuumdevice 130 are constructed to suck up and expel the spoil. Commercialexamples of suitable vacuum devices 110, 114, 130 are those made by SCAGGiant Vac., DR Power, and Billy Goat. The inlets 111, 115, 130 andoutlets 112, 116 of the vacuum devices can be conventional hoses, suchas 4 to 16 inch diameter hoses. The vacuum devices 110, 114 can alsohave a water misting system 148 that is attached to a water tank 150.The misting system 148 can be engaged manually or electronicallyprogrammed to emit a water mist inside the container 104 minimizingdust. The vacuum devices 110, 114, 130 can run on gas, diesel, electricor solar power. The vacuum devices 110, 114, 130 can have a steelimpeller inside that will allow for any debris to be pulverized orchopped into smaller pieces. The vacuum devices 110, 114, 130 can bemounted on a truck or can be on a trailer and hitched to a vehicle fortransportation. The vacuum devices 110, 114, 130 can be hooked updirectly to a vehicle gas tank in order to eliminate a separate fuelingmechanism. The vacuum fuel tank can have its own independent gas tankfueling mechanism. If one vacuum is used to do both intake and outtake,a secondary outtake valve 156 can be used for the spoil to be expelled.The intake valve 154 may need to be closed or shut off so no spoils willbe expelled out of the saw connection. The intake system 113 can alsohave a valve 152 for controlling the amount of spoil 12 to be removedfrom the container 104. The vacuum can have a CFM (Cubic Feet perMinute) throttle allowing the intake and outtake speeds to be adjustedbased on the operators requirements.

The present invention also relates to a continuous method of cutting amicrotrench 11, laying cable and/or innerduct/microduct 140 in themicrotrench 11, and then filling and sealing the microtrench 11 in onestep (also referred to as one pass) with the fill 212. An exemplarymethod is shown in FIGS. 3 and 4. A micro trencher 2 is used to dig atrench 11 and create spoil 12. The first vacuum device 110 is used tovacuum the spoil 12 from the trencher 2, preferably also from the trench11, and deposit the spoil 12 in the first container 104. Cable or duct140 is spooled from the reel 121 and laid in the trench 11. A filldevice 200 is then used to fill the trench 11 with fill 212 from anoutlet 210 to cover the cable or duct 140. The second vacuum device 114can be used to vacuum at least a portion of the spoil 12 from the firstcontainer 104 and transfer the spoil 12 to the fill device 200 to formthe fill 212 from the spoil 12. The trench can be filled with one ormore of the following examples, but not limited to, cement, grout, sand,self-leveling sealer, expansion joint, epoxy which is inserted into thetrench on top of the cable or innerduct/microduct.

A further exemplary method is shown in FIG. 5. A micro trencher 2 isused to dig a trench 11 and create spoil 12. The vacuum device 130 isused to vacuum the spoil 12 from the micro trencher 2, preferably alsofrom the trench 11, and deposit the spoil 12 in the first container 104.Cable or duct 140 is spooled from the reel 121 and laid in the trench11. A fill device 200 is then used to fill the trench 11 with fill 212from an outlet 210 to cover the cable or duct 140. The vacuum device 130can be used to vacuum at least a portion of the spoil 12 from the firstcontainer 104 and transfer the spoil 12 to the fill device 200 to formthe fill 212 from the spoil 12.

One or more spoil transport devices are utilized in the presentinvention to transfer spoil from the micro trencher 2, and optionallyalso the trench 11, and move the spoil 12 to first container 104, filldevice 200, trucks, and/or any other devices utilized in the presentinvention. FIGS. 1-8 illustrate embodiments of the spoil transportdevices comprising vacuum devices, as discussed above. Instead of vacuumdevices, the spoil transport devices can be a conveyor 300, a screw 302,or any other spoil moving device as shown in FIGS. 9A and 9B.Preferably, the spoil transport device for removing spoil from the microtrencher 2 and trench 11 comprises a vacuum device.

A particularly preferred flowable concrete-based fill 212 can be formedby mixing together a bonding agent comprising a polymer additive(polymer bonding agent), concrete mixture (cement and aggregate) and acoloring agent to complete the micro trench or shallow trenchbackfilling operation. The spoil 12 can be used as part of the flowableconcrete-based fill 212. A preferred commercial example of the polymerbonding agent is SC polymer by SureCrete, which can be found athttp://www.surecretedesign.com/product/liquid-concrete-polymer/.Examples of the polymer bonding agent include latex modified bondingagents, acrylics, epoxies, styrene-acrylics, vinyl acetate ethylene(VAE), polyvinyl acetate (PVA), and styrene-butadiene resins (SBR). Inliquid form, polymer bonding can be supplied in two parts, liquid andpowder, to be mixed together prior to use. In dry form, the polymerbonding agent can be prepackaged with desired materials blended forspecific applications. A preferred polymer bonding agent is an acrylicpolymer. The polymer bonding agent can be added to the flowableconcrete-based fill 212 in conjunction with substituting sand and/orspoil for conventional gravel aggregate to allow for use in the microtrench or shallow narrow trench application. By altering the slump orviscosity of the concrete by altering the water content we were able tocontrol the flow rate and application of the mixture into the narrowtrench. There are other commercially available bonding agents that willperform similar the product above. Polymer bonding agents for concreteare well-known in the art and any desired polymer bonding agent can beutilized to increase the bond between the set fill and the roadway inthe microtrench.

One of ordinary skill in the art will be able to adjust the viscosity ofthe bonding agent/concrete mixture fill 212 so that the fill 212 canflow into the shallow narrow trench, such as less than 2″ in width andfrom 2″ to 20″ in depth.

In comparison, previous to the present polymer bonding agent/concretemixture, we used concrete mixtures or asphalt mixtures as a the primarybackfill in the trench and then a chemical compound was utilized overtop of the mixture to seal the roadway from water intrusion. By usingthe concrete with the bonding agent in the trench we have eliminated theneed for multiple passes as the bonding agent will bond to the trenchand provide the necessary seal to the roadway. The chemical compoundsutilized previously in sealing the trenches are costly, slow to deployin some cases, and was required installation crews to complete multiplesteps in completing an operation. Furthermore, by coloring the bondingagent/concrete mixture to match the roadway color we have furtherreduced the cost of installation by completing the backfill in one stepand the coloring is similar to that of an existing roadway. The bondingagent provided the adhesion to the existing surface which in the pastwas completed with different much more expensive chemicals. The bondingagent/concrete mixture allows for the installation of a cement basedproduct with adhesive characteristics. Filling a microtrench in one stepusing a color matched bonding agent/concrete mixture instead of multiplesteps has not been done heretofore.

By pumping or using commercially available concrete installation tools,substituting sand and/or spoil for conventional stone aggregate,regulating the viscosity of the concrete product by adjusting the watercontent, adding the coloring agent to the concrete, and adding a bondingagent, we have developed a method of completing the shallow narrowtrench that is far faster and significantly more cost effective thanprior solutions that are utilized in the industry. This allows forsignificant cost savings compared to other methods of backfilling ashallow narrow trench.

The figures show exemplary devices for practicing the claimed inventionthat are now being used by the inventor to install optical fiber cablefor Google. The present invention allows surprisingly far faster andmore efficient installation of the optical fiber. For example, ourmultiple crews installing optical fiber cable for Google are installingfrom 4000 to 6000 feet of optical fiber cable per day. We believe up to7000 feet per day can be achieved. Conventional methods only allow about1000 feet per day. The present invention causes far less disruption ofroads and pathways. The present invention can also return the roads andpathways to their original state with the same colored fill. The presentinvention is not limited to the order of the devices and methodsillustrated in the figures and any desired order of devices and stepscan be utilized to practice the claimed invention.

In another embodiment, a marker line 400 as shown in FIG. 10 can beapplied to the surface 402 of the ground to be cut by the microtrencher. In this manner, utilities can see where the micro trench 11will be formed so that the utilities can mark locations of theirinfrastructure 410, such as electrical lines, optical cable, waterlines, sewer lines, or any other infrastructure. The marker line 400 canhave start 406 and stop 408 locations, and can identify the depth. Themarker line 400 can be a solid line, dashed, dotted, contain letters,numbers or symbols, and can be any desired color with white being themost preferred.

In another embodiment of the invention, a temporary fiber optic cablenetwork can be laid out on the surface and utilized as a temporaryoptical fiber network. The temporary optical fiber network can beprotected with any desired protection device, such as conduit, tarps,tape or other type of cover, that can be skid proof, and constructed foroutdoor use which can withstand foot and vehicle traffic. For example,the tape can be heated to activate an adhesive, or peelstick, silicone,epoxy glue or any desired type of adhesive. The surface can be a street,sidewalk, driveway, asphalt, concrete, dirt, interior floor, or anyother desired surface.

As shown in FIGS. 11A-11G, the temporary optical fiber network 500includes at least one optical fiber cable 502, and preferably aplurality of optical fiber cables 502. The optical fiber cables 502 canbe coiled on a reel 504 or loosely coiled 506. Each end of the opticalfiber cables 502 can have a first connector 514 installed thereon, or aconnector can be installed in the field by a technician. The opticalfiber cable 502 can be uncoiled to a desired distance and a protectiondevice 512, such as tape, applied thereover. A first end of the opticalfiber cable 502 can be connected to a desired feed using the firstconnector 514. The second end of the coil can be connected to anydesired location using the second connector 516. The connectors 514, 516can be connected to splitters 518 or any desired device. The desiredlocation can be dwelling, sporting event, military site, or any otherdesired location.

The reel 504 and loose coil 506 allows the fiber cable 502 to bedeployed to any desired length and also to be recoiled if necessary. Thesecond end connector 516 can be constructed so that the second endconnector 516 can remain connected while the reel 504 is rotated,similar in design to the Camplex reels. Alternatively, the second endconnector 516 can be disconnected while the reel 504 is rotated so thatthe connector 516 can rotate with the reel 504. The loose coil 506 orwound reel 504 can be installed within a box 520. The box 520 cancontain multiple reels 504 or coils 506. The box 520 can be formed fromplastic, metal, galvanized, stainless steel, concrete, fiberglass,rubber or any other suitable material. The reels 504 can be mounted onbracket(s) or rod(s) 522 that can be placed from side to side(horizontal) or from bottom to top (vertical). Spacers can be placed inbetween the reels so they can spin independently of each other. The box520 can have any desired shape, such as tubular, square, triangular,rectangular or any other desired shape. The box 520 can have a lid ordoor that can be locked or otherwise secured. The box 520 can be mountedon a roller. The box 520 can be buried, mounted pole, or secured in anydesired location.

The box 520 can have one or more optical fiber extenders, such as reels504 or loose coils 506, for input 534 to allow optical fiber cable 502to be unwound for a temporary or final installation. The box 520 canhave one or more optical fiber extenders, such as reels 504 or loosecoils 506, for output 532 to allow optical fiber cable 502 to be unwoundfor a connection(s) to and additional box(es) 520 for temporary or finalinstallation. The box 520 can have one or more optical fiber extenders,such as reels 504 or coils 506, for fiber drops 530 to allow opticalfiber cable 502 to be unwound for connections to customers for temporaryor final installation.

After using the temporary optical fiber network 500, once the desiredlocation of the optical fiber 502 and box(s) 520 are known, the opticalfiber network can be made permanent by removing the protection device512, creating slack in the optical fiber 502 by uncoiling the opticalfiber from the extenders in the box 520, creating a microtrench asdescribed herein, burying the optical fiber and covering the opticalfiber with a fill, and permanently mounting or burying the box(s) 520.

Fiber optic converter/extenders on a 1000 foot reel are known.Commercial examples are cmx-tacngo-sdi tac-n-go 3G sdi fiber opticconverter/extender, TAC1 Simplex LC fiber optic tactical cable reel, andTac-N-Go fiber optic by Camplex. www.camplex.com. These are fielddeployable optical fiber reel systems. Corning systems also providesfiber optic convert/extenders at any desired length, any number ofconnectors, such as 1 strand to 864 strands, usually from 6 strands to432 strands, and the fiber optic cables can be connectorized in field oralready have a connector applied. The known reels can be utilized in thepresent box 520 and permanently mounted.

The temporary taped optical fiber installation can be utilized toprovide an optical fiber network 500 to a desired user, such as aneighborhood, business, sporting event, military complex, or any otherdesired location. Once the desired location of the optical fiber isdetermined, slack can be provided in the optical fiber 502, the tape 512removed, a nanotrench or microtrench 11 can be formed, the optical fiber502 installed in the trench 11, and then the trench 11 can be filled 212using any desired method, such as the methods described herein above.Instead of the microtrench 11, the optical fiber can be mounted inconduits, drills, core drill, hung, walls, hydrovac, and/or directionaldrill. If the optical fiber 502 is on a reel 504 within the box 520, thebox 520 and reel 504 can be permanently mounted. In addition to the fill212 described above, the buried fiber cable 502 can be covered with selfleveling grout, caulking, asphalt, tar, SL1, cold patch, concrete,sterling Loyd, of other fill products.

The fill 212 can be covered with a spray on waterproofing sealer. Apreferred example is the TRANSLINE SOLVENT-BASED SOLID COLORWATERPROOFING SEALER AND TREATMENT—BLACK developed as a modification tothe Black Gorilla Paint, 22A-E001, to help with spraying the materialeasier. The TRANSLINE SOLVENT-BASED SOLID COLOR WATERPROOFING SEALER ANDTREATMENT—BLACK can be changed to the same formula as the Black GorillaPaint, 22A-E001. Alternatively, the Black Gorilla paint can be utilized.

The present invention includes a system, method and device forconnecting a fiber optic feeder cable 502, by the second connector 516,to a feeder line that supplies one or more signal types, such astelevision (TV), data (e.g., internet access), and telephone (fixedwireline or cellular), to a plurality of units (offices or dwellings) ina multi-unit building. In some example embodiments, the system, methodand device may be used to connect a new feeder line 502 to existinginternal wiring (twisted pair, coaxial cable, etc.). In addition oralternatively, the device can be used to connect a feeder line to awifi, local network, telephone network, or any other desired connectionwithin the building. The invention can also be used to supply aneighborhood. For example, if coax is already connected to an existingneighborhood, the coax can be connected to cards in a box and an opticalfiber cable 502 can used to input a feeder line into the input 534 ofthe box 520 so that coax does not have to be replaced savingconsiderable time and expense. In this manner the box can be placed on atelephone pole or near an optical fiber connection so that and opticalfiber cable 502 input can be connected to the multiple existing coaxcables.

Specifically, in many buildings it may be cost prohibitive and/orimpractical to run fiber optical fiber cable 502 to each unit. Inaddition, the various owners of units may want to purchase services thatrequire different drop connections (i.e., the wiring (twisted pair,fiber, coax, etc.) that connects the unit to the feeder line usingoptical fiber cable 502. In addition, it may be more economical to usean existing drop connection (e.g., twisted pair) for some services(e.g., telephone). For example, one dwelling unit may purchase onlytelephone service (which may employ a twisted pair drop connection),another dwelling unit may purchase telephone and television service(which may employ a coaxial cable or coax cable and twisted pair dropconnection), and yet another dwelling unit may purchase only internetaccess (which may employ a fiber conductor or coaxial cable dropconnection). Embodiments of the present invention may be used to servicebuildings to supply service to units using any of various mediaincluding twisted pair, coaxial cable, fiber optics, CAT-5 (Ethernet),and/or others. The disclosure in my previous U.S. Pat. No. 9,485,468 isincorporated herein by reference.

While the device for cutting a microtrench device is preferably utilizedto bury the temporary optical fiber network, any trenching device can beutilized. For example, the trench can be ⅛ inch to 1.5 inch wide and upto 6 inches deep when using the microtrenched, or 0.75 to 3 inches wide,and as deep as 24 inches for larger trenching devices.

As shown in FIGS. 12 and 13, the device identifier fill 902 below thesurface can comprise any desired fill material, for example, but notlimited to dirt, spoil, sand, concrete, or flowable fill that has beencolored, so that one or more specific color(s) identifies that a device900 is buried below the device identifier fill 902. The color(s) of thedevice identifier fill 902 can also identify the specific type of burieddevice 900. For example, the device identifier fill 902 can be tinted,dyed, or painted to any color(s) to signify the location and/or type ofburied device(s) 900. For example, a first color for electrical, asecond color for water conduit, a third color for sewer conduit, afourth color for cable, a fifth color for gas, a sixth color fortelecommunication devices, and additional colors can be used to identifycombinations of these buried devices 900 and/or other buried devices900. The communications devices can include any of optical fibers,connectors, amplifiers, and any device utilized in communications,including but not limited to television, radio, voice, and internet. Theburied devices 900 includes the multiple cables 140 and/or ducts orconduits 121. Orange or yellow is preferred for buried telecommunicationequipment and cables. Thus, when workers are digging, if they see thedevice identifier fill 902 in the ground or on the digging device theycan stop digging to avoid damaging the buried device(s) 900. The deviceidentifier fill 902 can be used in any application and is not limited tomicrotrenching. In this instance, the device identifier fill 902 can bethe fill 212, dirt or any material to which a coloring agent can beadded and then used to cover the buried device. The device identifierfill 902 can be used during burying any device 900 to identify thelocation and/or type of the buried device 900. In addition, whenmicrotrenching, the surface of the trench can be filled with the fill212 or surface coating having a color to substantially match thesurface, such as black for asphalt and white for cement, the belowground device identifier fill 902 can be utilized to identify the typeand/or location of the buried device(s) 902. Preferably, the coloringagent is non-toxic, environmentally friendly, and will not contaminateground water. Coloring agents, from paints and dyes, are now well knownand any suitable coloring agent can be utilized in the device identifierfill 902. A preferred coloring agent (colorant) is a powdered concretedye, such as those sold commercially from Quickrete, Stone Technologies,or DCI.

When utilizing the device identifier fill 902 in the microtrenching, thefill device 200 can fill the trench with the device identifier fill 902and then simply spray or apply a coating or top surface of fill 212 overthe device identifier fill 902. FIG. 13 illustrates the device 200applying the device identifier fill 902 first in the trench 11 above thecable 140, and then applying the colored fill 212 to match the surface.Alternatively, a coating can be sprayed or applied over the deviceidentifier fill 902 and/or over the fill 212.

The device identifier fill 902 can be any desired thickness above theburied device 900. Preferably, the device identifier fill 902 fills mostof the trench to provide a warning to construction workers digging overthe buried device 900. Examples of suitable thickness are from 1 to 36inches, preferably from 1 to 24 inches.

In addition to or in place of color, the device identifier fill 902 canincorporate other means to provide location and/or identification of theburied device 200.

Google has been aggressively attempting to copy the present fill 212having cement, polymer bonding agent, and coloring agent that cancontinuously fill and seal the microtrench 11 in a single continuousstep to provide a sealed microtrench 11 that substantially matches thecolor of the roadway in one pass. Google has tried numerous concretetype materials, such as Fast Patch which a well-known concrete crackrepair product. However, the fill material based on Fast Patch oozed outof the microtrench and did not adequately seal the microtrench. Googlealso tried numerous tar based sealants, such as Craftco, to try and seala microtrench. However, in one example, an inspector for the city of SanAntonio was able to easily peel the Craftco tar fill from themicrotrench like peeling tape. Conventional cement crack repair productsare not known for successfully filling and sealing a microtrench. It isnot obvious to use common crack repair and polymer containing materialsto fill a microtrench in a roadway. The present invention requiredsignificant research and testing to discover a fill 212 that exhibits afast final set (2 hours or less), high adhesion characteristics, lowpermeability, and a high density to provide a sealed microtrench thatwill not fail under exposure to the environment and vehicle traffic.

Concrete usually has a final set within 24-48 hours. Initial and finalset times as used herein are measured at 72° F. (22° C.) ASTM C 191 forhydraulic cement. The fill 212 is similar to hydraulic cement in that itis similar to mortar and must prevent water infiltration into the sealedmicrotrench 11. The initial set time is calculated as the time elapsedbetween the initial contact of cement and water and the time when theneedle penetration into the cured fill is at 25 mm. The final set timeis calculated as the time elapsed between the initial contact of cementand water and when the needle does not sink visibly into the cured fill.In the present invention, where microtrenching is continuous, laying theoptical fiber in the microtrench 11 is continuous, and thenfilling/sealing the microtrench 11 with the fill 212 is a continuoussingle step, the fill 212 has a final set time of less than 2 hours,preferably less than 1 hour, and more preferably in about 30-40 minutes.The final set time of the fill 212 can be adjusted by using fastercements, such as calcium sulfoaluminate cement, and/or by using a cementaccelerator. The fill 212 exhibits a compression strength sufficient forvehicular traffic to pass over the microtrench 11 without damaging thecured fill in the microtrench 11 in a far shorter time period than priorart methods of filling a microtrench.

Examples of cement accelerators include calcium nitrate (Ca(NO₃)₂),calcium formate (Ca(HCOO)₂), sodium nitrate (NaNO₃), calcium chloride(CaCl₂)) and calcium sulfoaluminate cement. Further examples includesalts of nitrate (for setting), thiocyanate (for hardening),triethanolamines, alkanolamines, carboxylic acids, sulphates, andaluminum sulphate. The accelerator can be added in an amount to providea desired fill curing rate in the microtrench, such as a final set timeof 6 hours or less, preferably 4 hours or less, and most preferably 2hours or less.

Conventional fill devices 200, as shown if FIGS. 3 and 4, typically havemultiple containers, such as dry containers that can be used for storingthe cement, powdered dye, cement accelerator, aggregate, and any otherdry materials, and liquid containers that can be used for storing water,liquid bonding agent, and any other liquids. The conventional filldevices 200 also can contain a mixed fill container which holds theformed flowable concrete-based fill material 212, proportioning systemsfor selecting amounts of dry materials and liquids to combine, mixingdevices for mixing the dry materials and liquids, and deliverymechanisms for delivering the formed flowable concrete-based fillmaterial 212 to the microtrench 11. Commercial examples of conventionalfill devices 200 include the volumetric concrete mixers sold by CemenTech, such as the M and C series trucks, shown at www.cementech.com.Thus, using the conventional fill device 200, the cement, cementaccelerator, aggregate, bonding agent, colorant, and water can bestored, mixed as desired, and then applied to the microtrench in lessthan 2 hours after mixing, preferably less than 1 hour after mixing, andmost preferably the fill material 212 is formed and applied to themicrotrench 11 in real time. In this manner, the steps of filling,sealing and coloring the microtrech can be conducted in one stepcontinuously as discussed herein, without requiring multiples passesover the microtrench 11. The fill device 200 can follow behind themicrotrencher 2 as shown in FIGS. 3-5 to provide a method ofcontinuously cutting the microtrench 11, laying the optical fiber and/orinnerduct/microduct in the microtrench 11, and filling the microtrench11 with the flowable concrete-based fill 212 in one pass, without havingto conduct multiple passes.

A preferred fill 212 for use in the present invention is formed bymixing together a polymer bonding agent, portland cement, calciumsulfoaluminate cement, a colorant, aggregate, and water. The fill 212ingredients can be mixed in a conventional fill device 200 just beforesimultaneously filling and sealing the microtrench in one step, toprovide a sealed microtrench having a color substantially the same asthe roadway to put the roadway substantially back to an original statebefore cutting the microtrench

A particularly preferred flowable concrete-based fill 212 can be formedby mixing together the bonding agent SC polymer, Fastrack 400 portlandcement from Western Material & Design (mixture of Portland cement andcalcium sulfoaluminate cement), LLC, a concrete dye, aggregate andwater. The water is added in a sufficient amount to provide a desiredviscosity and flow rate from the fill device 212 to fill and seal theentire microtrench 11 in one pass. This preferred fill 212 exhibitedminimal shrinkage (0.020% after 28 days using ASTM C157, air cure),which is far less than conventional cement/sand mixtures. Reducedshrinkage provides a better bond to the microtrench 11 and also an evensurface with the surrounding roadway. Using ASTM C39, the fill 212exhibited a compressive strength after 2 hours 3,500 psi (24.1 MPa); 3hours 4,300 psi (29.6 MPa); 1 day 5,740 psi (48.3 MPa); 7 days 6,680 psi(48.3 MPa); and 28 days 7,260 psi (55.2 MPa). Thus, the fill 212exhibited a compression strength sufficient for vehicular traffic topass over the microtrench 11 without damaging the cured fill in themicrotrench 11 in a far shorter time period than prior art methods offilling a microtrench. Conventional cement/sand formulations have asubstantially lower compressive strength. The bonding agent provided asufficient bond to the sides of the road in the microtrench 11 toprevent water penetration into the sealed microtrench 11, so that thesealed microtrench 11 will not be adversely affected during freezing andthawing throughout the seasons.

The cement, cement accelerator, polymer bonding agent, colorant, andaggregate can be added in the amounts necessary to provide the requiredproperties to fill and seal the microtrench 11 for vehicular use andexposure to the environment, and provide a final set time of 2 hours orless, as discussed above. Exemplary amounts include, based on weight %of the entire fill 212, when a cement accelerator is utilized:

-   -   1-80% cement accelerator;    -   1-80% cement;    -   0.01-5% colorant;    -   0.01-20% polymer bonding agent;    -   1-80% aggregate; and    -   10-80% water in an amount to provide flowable fill.

When a faster setting cement, such as calcium sulfoaluminate cement, isutilized, exemplary amounts include, based on weight % of the entirefill 212, when a cement accelerator is utilized:

-   -   0-80% cement accelerator;    -   1-80% cement;    -   0.01-5% colorant;    -   0.01-20% polymer bonding agent;    -   1-80% aggregate; and    -   10-80% water in an amount to provide flowable fill.

When burying telecommunications cable, such as optical fiber, additionalprotection can be added such steel plate above the cable and or a steelconduit around the cable.

It is to be understood that the foregoing illustrative embodiments havebeen provided merely for the purpose of explanation and are in no way tobe construed as limiting of the invention. Words used herein are wordsof description and illustration, rather than words of limitation. Inaddition, the advantages and objectives described herein may not berealized by each and every embodiment practicing the present invention.Further, although the invention has been described herein with referenceto particular structure, materials and/or embodiments, the invention isnot intended to be limited to the particulars disclosed herein. Rather,the invention extends to all functionally equivalent structures, methodsand uses, such as are within the scope of the appended claims. Thoseskilled in the art, having the benefit of the teachings of thisspecification, may affect numerous modifications thereto and changes maybe made without departing from the scope and spirit of the invention.

1. A method of continuously filling and sealing a microtrench containingan optical fiber and/or innerduct/microduct on a roadway to return theroadway to substantially an original state with a color-matched, filledand sealed microtrench comprising: forming a flowable concrete-basedfill in a fill device by mixing together a cement, a polymer bondingagent, a colorant, an aggregate, and water, wherein the colorantprovides the flowable concrete-based fill with a color substantiallymatching the color of the roadway, the polymer bonding agent providesadhesion to the existing roadway to seal the microtrench against waterinfiltration, the flowable concrete-based fill having a final set timeof 2 hour or less, and the flowable concrete-based fill is configured toflow into the microtrench from a fill device; and continuously fillingthe microtrench with the flowable concrete-based fill material from thefill device to cover the optical fiber and/or innerduct/microduct, filland seal the microtrench and return the roadway substantially back to anoriginal state with the color-matched, filled and sealed microtrench. 2.The method according to claim 1, further comprising mixing a cementaccelerator into the flowable concrete-based fill in an amount toprovide the flowable concrete-based fill with a final set time of lessthan 2 hours.
 3. The method according to claim 1, wherein the cementcomprises calcium sulfoaluminate cement in an amount to provide theflowable concrete-based fill with a final set time of less than 2 hours.4. The method according to claim 1, further comprising forming theflowable concrete-based fill in real time and filling the microtrench bythe fill device in real time.
 5. The method according to claim 1,further comprising mixing a cement accelerator into the flowableconcrete-based fill in an amount to provide the flowable concrete-basedfill with a final set time of less than 1 hour.
 6. The method accordingto claim 1, wherein the cement comprises calcium sulfoaluminate cementin an amount to provide the flowable concrete-based fill with a finalset time of less than 1 hour.
 7. The method according to claim 1,further comprising forming the flowable concrete-based fill so that theflowable concreted-based fill flows from the fill device into themicrotrench having a width of less than 2 inches and a depth of 2 inchesto 20 inches.
 8. The method according to claim 1, wherein the roadwaycomprises asphalt or concrete.
 9. The method according to claim 1,wherein the aggregate comprises sand.
 10. The method according to claim1, wherein the aggregate comprises spoil formed by ground up roadwayfrom cutting the microtrench in the roadway.
 11. The method according toclaim 1, further comprising continuously cutting the microtrench using amicrotrencher, continuously laying the optical fiber cable orinnerduct/microduct within the microtrench, and the fill devicefollowing behind the microtrencher continuously filling the microtrenchwith the flowable concrete-based fill.
 12. The method according to claim11, further comprising continuously transporting at least a portion of aspoil from the microtrencher to a first container constructed to containthe spoil using at least one spoil transporting device; and continuouslylaying the cable and/or innerduct/microduct in the micro-trench from areel device.
 13. The method according to claim 12, wherein the steps ofcontinuously transporting the spoil from the micro-trencher to the firstcontainer constructed to contain spoil using a first spoil transportingdevice and continuously laying at least one of the cable andinnerduct/microduct in the micro-trench from a reel device are conductedusing the micro-trencher using a multifunctional reel carrier, spoilmaterial handling container device comprising: a first truck or firsttrailer; the first container constructed to contain the spoil being onthe first truck or first trailer; and the at least one spoiltransporting device constructed to transfer the spoil from the microtrencher and deposit the spoil in the first container.
 14. The methodaccording to claim 13, further comprising using at least one spoiltransporting device to transport the at least a portion of the spoilfrom the first container to the fill device, wherein the aggregatecomprises at least a portion of the spoil.
 15. A method of continuouslyfilling and sealing a microtrench containing an optical fiber and/orinnerduct/microduct on a roadway to return the roadway to substantiallyan original state with a filled and sealed microtrench comprising:forming a flowable concrete-based fill in a fill device by mixingtogether a cement, a polymer bonding agent, an aggregate, and water,wherein the polymer bonding agent provides adhesion to the existingroadway, the flowable concrete-based fill having a final set time of 2hour or less, and the flowable concrete-based fill is configured to flowinto the microtrench from a fill device; and continuously filling themicrotrench with the flowable concrete-based fill material from the filldevice to simultaneously cover the optical fiber and/orinnerduct/microduct, fill and seal the microtrench and return theroadway substantially back to an original state with the filled andsealed microtrench.
 16. The method according to claim 15, furthercomprising mixing a cement accelerator into the flowable concrete-basedfill in an amount to provide the flowable concrete-based fill with afinal set time of less than 2 hours.
 17. The method according to claim15, wherein the cement comprises calcium sulfoaluminate cement in anamount to provide the flowable concrete-based fill with a final set timeof less than 2 hours.
 18. The method according to claim 15, furthercomprising forming the flowable concrete-based fill in real time andfilling the microtrench by the fill device in real time.
 19. The methodaccording to claim 1, further comprising mixing a cement acceleratorinto the flowable concrete-based fill in an amount to provide the fillwith a final set time of less than 1 hour.
 20. The method according toclaim 15, wherein the cement comprises calcium sulfoaluminate cement inan amount to provide the fill with a final set time of less than 1 hour.21. The method according to claim 15, further comprising forming theflowable concrete-based fill so that the flowable concreted-based fillflows from the fill device into the microtrench having a width of lessthan 2 inches and a depth of 2 inches to 20 inches.
 22. The methodaccording to claim 15, wherein the roadway comprises asphalt orconcrete.
 23. The method according to claim 15, wherein the aggregatecomprises sand.
 24. The method according to claim 15, wherein theaggregate comprises spoil formed by ground up roadway from cutting themicrotrench in the roadway.
 25. The method according to claim 15,further comprising continuously cutting the microtrench using amicrotrencher, continuously laying the optical fiber cable orinnerduct/microduct within the microtrench, and the fill devicefollowing behind the microtrencher to continuously fill the microtrenchwith the flowable concrete-based fill from the fill device.
 26. Themethod according to claim 25, further comprising continuouslytransporting at least a portion of a spoil from the microtrencher to afirst container constructed to contain the spoil using at least onespoil transporting device; and continuously laying the cable and/orinnerduct/microduct in the micro-trench from a reel device.
 27. Themethod according to claim 26, wherein the steps of continuouslytransporting the spoil from the micro-trencher to the first containerconstructed to contain spoil using a first spoil transporting device andcontinuously laying at least one of the cable and innerduct/microduct inthe micro-trench from a reel device are conducted using themicro-trencher using a multifunctional reel carrier, spoil materialhandling container device comprising: a first truck or first trailer;the first container constructed to contain the spoil being on the firsttruck or first trailer; and the at least one spoil transporting deviceconstructed to transfer the spoil from the micro trencher and depositthe spoil in the first container.
 28. The method according to claim 27,further comprising using at least one spoil transporting device totransport the at least a portion of the spoil from the first containerto the fill device, wherein the aggregate comprises at least a portionof the spoil.
 29. A roadway having a color-matched, filled and sealedmicrotrench containing an optical fiber and/or innerduct/microductformed solely by a flowable concrete-based fill that filled themicrotrench according to the method of claim
 1. 30. A roadway having afilled and sealed microtrench containing an optical fiber and/orinnerduct/microduct formed solely by a flowable concrete-based fill thatfilled the microtrench in one step according to the method of claim 15.